How to Make a Plywood Packframe

Backpacks combine internal frames made from many types of materials, such as aluminum and carbon fiber, with a packsack of a set size. They work well for backpacking with typical camping gear, but not so well when hauling an odd-shaped or heavy load, such as a chainsaw or a moose quarter. For loads like that, a traditional packframe, also called a packboard, loads more easily and carries more. Traditionally, hardwood formed the structure of a packframe, but plywood works just as well.

Things You'll Need

  • Saw
  • Plywood, 1/4-inch and 3/4-inch
  • 10 wood screws, 1-inch
  • Wood screws, 3/4-inch and 1 1/2-inch
  • Screwdriver
  • Pine board, 3/4- by 1 1/2-inch
  • Roofing nails, 3/4-inch
  • Shoulder straps
  • Webbing, 2-inch
  • Washers, 3/16-inch
  • Waist belt
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Instructions

    • 1

      Cut a piece of 1/4-inch plywood to the size of packframe you want to build with the saw. For an adult, 18 by 24 inches is recommended; for a child, 16 by 24 inches.

    • 2

      Cut two side pieces from 3/4-inch plywood. A side piece measures 24 inches long and 2 5/8 inches wide. The side pieces have curves. Make a mark 5 inches from one end and 8 inches from the other. Make a mark centered between the first two marks and 1 inch away from the side. Draw a curve connecting the marks. Draw a second curve on the side you measured 8 inches for the first curve. Start the curve 4 3/4 inches away from the end. Finish it on the end of the board and 1inch deep. Cut out the curves.

    • 3

      Screw the side pieces onto the plywood frame using 10 1-inch wood screws. Use a screwdriver to screw the screws in. Keep the outside of the side pieces flush with the outside of the frame.

    • 4

      Use a saw to cut a 3/4- by 1 1/2-inch pine board 14 1/2 inches long for a child's pack or 16 1/2 inches long for an adult pack. This is the strap bar.

    • 5

      Use 3/4-inch roofing nails to attach your shoulder straps to the strap bar's center.

    • 6

      Screw the strap bar to the frame with 3/4-inch wood screws. Screw it so it aligns evenly between the curves of the side pieces. Start the screws from the plywood frame side. Then screw into side pieces with 1 1/2-inch wood screws so the screws penetrate the end of the strap bar.

    • 7

      Drive screws through the ends of a piece of webbing that runs between the side pieces at the strap bar and another on the bottom of the pack. When screwing the bottom strap, use the same screws to attach the bottom of your shoulder straps to the pack. Use washers between the webbing and the screws' ends to prevent the webbing from pulling out. Use two screws per piece of webbing.

    • 8

      Screw the left side of the waist belt to the bottom outside left of the side pieces. Use two 3/4-inch wood screws and washers. Attach the other side of the waist belt to the right side piece.